CI-007 Level Gauges Installation,Operation and Manitenance Manual

MGP-GEN-ICS-MAN-SAI-000-00010-00-U-01 Page 1 of 16 MGP-GEN-ICS-POR-HEC-000-00007-00 SAMIL INDUSTRY CO.,LTD.

PROJECT : MUSANDAM GAS PLANT PROJECT

LOCATION : MUSANDAM, SULTANATE OF OMAN

COMPANY : OMAN OIL COMPANY EXPLORATION & PRODUCTION LLC

PO NUMBER : MGP-GEN-ICS-POR-HEC-000-00007-00

ITEM : LEVEL GAUGE

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

DOC # MGP-GEN-ICS-MAN-SAI-000-00010-00-U-01

U-01 15-Mar-13 ISSUED FOR CONSTRUCTION L.Y.B S.S.K H.G.H

K-00 09-Dec-12 ISSUED FOR INFORMATION L.Y.B S.S.K H.G.H

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

SAMIL INDUSTRY CO.,LTD

DOCUMENT STATUS

□ 1 : Approved

□ 2 : Approved with Comments

□ 3 : Not Approved

□ 4 : Information Only

NOTE: Permission to proceed does not constitute acceptance of

approval of design details, calculations, analysis, test methods or

materials developed/selected by the Supplier and does not relieve

the Supplier from full compliance with contractual obligations.

REVIEW DATE: . . .

ENGINEER LEAD ENGINEER

9940169

승인됨

9940169

입력 텍스트

27th Mar. 2013

9940169

입력 텍스트

Y.R.JEONG

9940169

입력 텍스트

C.W.BAK

Musandam Gas Plant Project Installation, Operation And Maintenance Manual


REVISION LOG

REV. NO.

REV. DATE REVISED PAGE

REVISION DESCRIPTION

K-00 09-Dec-12 Issued for Information

U-01 15-Mar-13 Issued for Construction

Musandam Gas Plant Project Installation, Operation And Maintenance Manual


TABLE OF CONTENTS

1. INSTALLATION, OPERATION AND MAINTENANCE MANUAL………………….4

No. : SICS-03-02

SAM IL INDUSTRY CO.,LTD

Installation · operation

and maintenance manual PAGE : 1 OF 5

MAGNETIC FLOAT TYPE LEVEL GAUGE

[MODEL : SMF-50A,65A, 50AN, 50AJ, 50ALD, 50AU]

0 04.01.2004 First Issue M.Y CHOI E.M JEONG K.T CHOI

Rev. No. M . D . YEAR Rev. Description Prepared By Reviewed By Approved By

FORM NO. : SICS-03-02 REV.0 QUALITY NOW….！

No. : SICS-03-02




Table of Contents

1. Things to Check before Installation------------------------------------- 3

2. Test Operation Procedure------------------------------------------------ 3

3. Cause for malfunctioning FLOAT ---------------------------------------- 4

4. LEVEL GAUGE Maintenance/Repair----------------------------------------- 4

◈ Disassemble and assemble.

5. Precautions ------------------------------------------------------------ 5


No. : SICS-03-02




1. Things to Check before Installation

1) Check to see if there are any damages done during the transportation.

2) Check to make sure there are no foreign objects like dirt or rocks within the pipes of

Tank(Vessel), and connection part of the flange (It is to insure the proper operation of the float)

3). In order to prevent the malfunction of the float caused by leakage in Level Gauge or torsion of

the column, the section drawing of the flange face, aligned bolt hole of the flange, distance in

between C to C, and the height of the Flange face must be checked.

4) Please remove the spring that was installed within the chamber to prevent the movement of the

float [Refer to the picture in PAGE 4 OF 5].

2. Test operation procedure

The most important part of the Magnetic Float Type Level Gauge is the float. Therefore, it is

important not to harm the Float part during the test operation, The fluid used in the Float is

designed to the pressure and the temperature used in the normal operating condition.

Therefore, it is important to set the environment to the standards of normal operating condition

before performing the test operation. The high temperature (100 C) liquid must be dealt with

special care. The float is not designed to be operated in the worst condition. Please careful not

to damage the float part.

※ Sudden change in the pressure or temperature could damage the float

※ In the case of pressure is inflow suddenly inside the chamber, the float can crush or

deform by striking into an upper blind of the chamber.

In order to prevent the above, be sure to follow the below order without fail.

1). Open the upper valve very slowly, so that the pressure and fluid increases very slowly

inside the float chamber.

repeat 4 ~ 5 time that opening and closing the upper valve very slowly.

2). If the temperature of the Level Gauge Body(Column) reaches the operation temperature,

fully open the upper & lower block valve to fill in the level gauge with the liquid.

3). If there are no problems with the Float, the level gauge indicator will mark the liquid level of

the tank as it is. (±10 cm difference could occur due to the temperature difference in

between the tank and the level gauge)


No. : SICS-03-02




3. Cause of malfunctioning FLOAT.

1). Distortion or damage to the Float

2). Ration difference in between the Float and the operating liquid.

3). Foreign object within the interior of the Level Gauge Body(Column)

and blocking the movement of the Float.

4). Due to the disclosure or malfunction of the Drain Valve, liquid is

not filled up fully into the Level Gauge Body(Column)

5). During the installation of the level gauge, the spring to prevent

the movement of the body during the shipment was not

removed

4. LEVEL GAUGE Maintenance and Repair

If there are no damages done to the float, the operation and maintenance of the Magnetic Float

Type Level Gauge is not difficult at all. If the color of the Indicator is changed, it must be

exchanged in a periodical basis.

◈ Assemble and Disassemble.

Due to simple structure of the Magnetic Float Type Level Gauge (Picture-1), it can be easily

disassembled and assembled. If the exchange of the float and the cleaning of the Level

Gauge Body (Column) is needed, the following procedure could be followed.

① Close the upper and lower block valve.

② Open the Drain Valve to relieve the inner pressure and liquid. (If it is a hot liquid, the Level

Gauge will also be very hot. Be careful for the burn)

③ Loose the bolt & nut of the Bottom Blind Flange Bolt & Nut and disassemble the blind flange.

Then, take out the float. Be careful not to drop the float.

④ Check to see if the Float is in good condition.

⑤ If the Float is in good condition, it could be reused.

⑥ The assemble of the equipment could be done by following the disassemble procedure

backward.

Do not put the Float into the Level Gauge. Set the Bottom Blind Flange, and tighten it with

the Bolt & Nut. The Gasket must be exchanged with a new product.

⑦ The test operation procedure is the same with the test operation procedure in article 2


No. : SICS-03-02




5. Precautions

During the final test of the Tank(Vessel), there may be cases where the Magnetic Float Type Level

gauge must be installed and operated in the same time. In this case, the maximum operation

pressure is set as 1.5 times greater than the designed pressure. In this case, please remove the float

before the test operation. (If the float is operated under an irregular condition, it may be

damaged.)


NO. : SICS-03-02


INSTALLATION·OPERATION AND

MAINTENACE PROCEDURE PAGE : 1 OF 8

TUBULAR, REFLEX, TRANSPARENT TYPE

LEVEL GAUGE

[MODEL : SBG-1,2,3 & SRG-1,2,3,4 & STG-1,2,3,4]

0 04.01.2004 First Issue M.Y CHOI E.M JEONG K.T CHOI

Rev. No. M . D . YEAR Rev. Description Prepared By Reviewed By Approved By


NO. : SICS-03-02




TABLE OF CONTENTS

1. THINGS TO CHECK BEFORE INSTALLATION ----------------------------------- 3

2. CAUTIONS FOR VENT AND DRAIN PIPING ------------------------------------ 3

3. THE ORDER OF MAKING A TRIAL RUN AND CAUTIONS -------------------------- 3

1) CONFIRMATIONS BEFORE A TRIAL OPERATION

2) THE ORDER OF A TRIAL OPERATION

4. TROUBLESHOOTING FOR THE MALFUNCTIONS OR TROUBLES ---------------------- 4

5. DISASSEMBLING AND ASSEMBLING ------------------------------------------ 4

[1] TUBULAR TYPE LEVEL GAUGE ------------------------------------------- 4

1) THE ORDER OF DISASSEMBLING

2) THE ORDER OF ASSEMBLING

A) GLASS TUBE

B) HOSE(PFA)

[2] REFLEX, TRANSPARENT TYPE LEVEL GAUGE ------------------------------ 6

1) THE ORDER OF DISASSEMBLING

2) THE ORDER OF ASSEMBLING

3) HYDROSATIC OR PNEUMATIC TEST AFTER ASSEMBLING


NO. : SICS-03-02




1. THINGS TO CHECK BEFORE INSTALLATION

1). Make sure that a leak on the connected parts of the level gauge or the distance from center to

center in order to prevent fracture or damage of the glass, a parallel level of flange face, the

P.C.D of bolt holes of the level gauge flange and counter-part. also, whether the height of

flange face is equivalent or not.

2) Make sure of no mud, welding slag, dust, etc inside of tank (vessel) pipe and the flange.

3) In case of check ball type, confirm if the check ball is set properly to the gauge valve.

4) Confirm if the gasket of the flange to be connected is suitable for the operating condition.

(like as fluid state, temperature , pressure and type).

5) Make sure of the Tag no., required material and etc.

2. CAUTIONS FOR VENT AND DRAIN PIPING

1) The vent and drain piping are required for operator’s safety when fluid is drained or vented.

2) SAM IL’s standards of vent and drain are 1/2” NPT and 15A PT.

as customer’s requirement, other size [3/4”, 1”] can be supplied.

3. THE ORDER OF MAKING A TRIAL RUN AND CAUTIONS

1) Confirmations prior to a trial operation

① No damage or breakage of glass.

② Make sure that the vent, drain valves or plug shall be closed totally.

2) The order of a trial operation (Refer to Fig.-1)

① Fully close the upper(A), lower valves (B) and drain valve(C)

② Open the drain valve (C)

③ Gradually open the upper valve(A) and eliminate air in the level gauge.

④ Fully close the drain valve (C) to give pressure same as the vessel(tank) to the level

gauge. if the temperature of fluid is high or low, preheating or pre-cooling have to be

applied to prevent thermal shock. If the fluid is high temperature, leakage can occur from

gasket due to thermal expansion of the bolt. Make sure to wait until the level gauge turn

into stabilized to the operating temperature.


NO. : SICS-03-02




⑤ Gradually open lower valve(B) to in-flow the fluid to the level gauge from the vessel.

⑥ Finally, open the upper and lower valves fully. With improper opening, the ball check can’t

give its function fully.(Refer to Fig.-2)

BALL CHECK OPERATED

BALL CHECK NOT OPERATED

BALL CHECK

Fig.-1 Fig.-2

4. TROUBLESHOOTING FOR THE MALFUNCTION OR TROUBLES.

1) When leakage occurs on the Level gauge body, close the upper and lower valves and open

drain valve to depressurize interior of the level gauge (in accordance with No.5).

2) When leakage occurs on the connection between gauge body and gauge valve, depressurize

interior of the level gauge like No.1 and loose connection nut and replace the gasket.

3) When liquid level is not indicated in the level gauge.

① In case of ball check’s trouble, fully close the upper and lower valves and then gradually

open them slightly.

② In case that upper and lower valves are choked with something wrong, close the block

valve and dismantle the level gauge and clean it up.

③ In case Drain Valve is set closed or leaked, confirm if the drain valve is closed or leaked.

(If leakage occurs on the valve, replace it.)


NO. : SICS-03-02




5. DISASSEMBLING AND ASSEMBLING (=MAINTENANCE).

[1] disassembling and assembling procedure for tubular type level gauge .

1) disassembling (Refer to Fig.-3)

① Close the gauge valve (lower, upper) and open the drain valve to eliminate the fluid and

pressure.

② Loose hose band[1] and union nut[3] and separate the glass(or hose) and protector from

valve.

③ Remove them carefully for preventing damages.

2) Reassembling (Refer to Fig.-3)

A) In case of glass tube.

① Loose the union Nut[3] of gauge valve and set it to glass tube[6].

② Set gland[4] to glass tube with union nut and then set packing[5:Gasket] to it.

③ After following ① & ②, set the glass tube to gauge valve.

④ Push gland to gauge valve and fix gland and packing into the gauge valve.

⑤ For no leakage, fasten union nut properly so far as glass can’t be breakable.

⑥ With control of C to C, fix the protector[2] to gland of gauge valve.

⑦ Fasten the protector firmly with hose band[1].

TUBULAR TYPE LEVEL GAUGE

Fig.-3

B) In case of hose (PFA).

① Loose the union nut[3] of gauge valve and set it to hose[6].

② Set gland[4] to hose with union nut.

NO. NAME OF PARTS

1 Hose Band

2 Protector

3 Union Nut

4 Gland

5 Packing / Hose Nipple

6 Glass / PFA Hose


NO. : SICS-03-02




③ After heating the end of hose (until it becomes smooth), insert it into hose nipple[5].

④ Fix hose nipple with hose to gauge valve.

⑤ Push gland to gauge valve and fix the union nut.

⑥ Fasten the union nut firmly for no leakage.

⑦ With control of C to C, fix the protector[2] to gland of gauge valve.

⑧ Fasten the protector firmly with hose band[1].

[2] Disassembling and Assembling procedure for Reflex, Transparent type Level Gauge

1) disassembling (Refer to fig.-4)

① Close the gauge valve (lower, upper) and open the drain valve to eliminate the fluid and

pressure.

② Remove the accessories (Illuminator, non-frost, etc)

③ Unfastening nut[7], separate the cover from body and then detach the glass.

④ Remove the gasket[2] and cushion gasket[4] carefully for no scratch or any damage on it

because gasket adhere to Body firmly for long time. at this point of the above, make

sure that there is no scratch or any damage on its surface (leakage may occur).

2) Reassembling (Refer to Fig.-4)

① Clean a contacted face with gasket of Level gauge. If not, leakage may occur.

② In case of Reflex type level gauge, put in order the Gasket[2], Glass[3] Cushion

Gasket[4] on a contacted face with gasket of Level gauge. In case of Transparent type

Level gauge at high temperature or corrosive fluid, put in order the Gasket[2], Mica[9],

Glass[3], Cushion Gasket[4] on a contacted face with gasket of Level gauge.

� Additionally put in the Mica[9] for protecting the glass.

③ Put bolts into the holes of the cover and fasten them with washer[6] and nut[7] smoothly.

For re-using bolts, make sure conditions for corrosion of bolts and thread of screw.

④ Confirm if Gasket, Glass and etc are set correctly in their places and fasten the bolts with

50~100kgf-cm Torque for first time bolting.

⑤ Make sure for the above again and then re-bolt them with maximum value of torque.

If torque value is high for high-pressure, bolt them into 3~5 times.

At the point of the above, make sure to follow the procedure in accordance of fig-5. If it’s

not, leakage may occur. Also be careful that glass can be broken when excessive

pressure apply. ( apply the uniformed torque among all cover).


NO. : SICS-03-02




Fig.-4

FASTENING TORQUE [kgf-cm ]

NO NAME OF PART NO MODEL PRESSURE 1ST 2ND 3RD 4TH 5TH 6TH

1 Gauge Body 1 STG-1 30kgf/cm2 100 200 350

2 Gasket 2 STG-2 50kgf/cm2 100 200 400

3 Glass 3 STG-3 80kgf/cm2 100 200 400 500

4 Cushion Gasket 4 STG-4 180kgf/cm2 100 200 400 500 600

5 Gauge Cover 1 SRG-1 30kgf/cm2 100 200 400

6 Washer 2 SRG-2 50kgf/cm2 100 200 400

7 Nut 3 SRG-3 100kgf/cm2 100 200 400 600 700

8 Bolt 200kgf/cm2 100 200 400 600 800

9 Shield(MICA)

4 SRG-4 250kgf/cm2 200 500 800 1000 1200 1400


NO. : SICS-03-02




※ The above table is torque values for using the non-asbestos gasket and for using 320

mm of the glass length. the torque values may be changed a bit according to gasket

material and glass length.

TRANSPARENT & REFLEX TYPE LEVEL GAUGE

Fig.-5

⑥ At the point of the above, make sure to follow the procedure in accordance with Fig.-5.

If does not, leakage may occur. Also be careful that glass can be broken when excessive

pressure apply. ( apply the uniformed torque among all covers).

⑦ Replace the gasket, cushion gasket and etc with new one surely.

If re-use them, leakage may occur.

3) Hydrostatic (or Pneumatic) test after assembling.

※ First of all, operate the pressure test with it greater than operating pressure.

- Hydrostatic test : Operating pressure x 1.5 for 5 minutes (SAMIL’s standard)

- Pneumatic test : Operating pressure x 1.1 for 5 minutes (SAMIL’s standard)

4) After setting up, warming up in accordance with clause 3.


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CI-007 Level Gauges Installation,Operation and Manitenance Manual

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